In an era where efficiency, safety, and agility are paramount, manufacturing facilities are rapidly turning to intelligent technologies to future-proof their operations. Traditional surveillance systems, once purely reactive, are being transformed by powerful integrations that enable them to play an active role on the shop floor.
This transformation hinges on a set of key technologies: MQTT / OPC UA, Audio-over-IP, and Video Management Systems (VMS). Individually, each of these technologies provides substantial benefits.
Together, they unlock a new level of real-time automation, predictive insight, and safety compliance. This article explores how these systems interconnect to form the foundation of the next-generation smart factory.
MQTT: Real-Time Communication Between Cameras and Machinery
MQTT (Message Queuing Telemetry Transport) is a lightweight messaging protocol designed for efficient, low-bandwidth communication between devices. In manufacturing, it’s increasingly being used to connect cameras, sensors, and factory machinery—allowing them to “talk” to each other in real time.
When integrated with intelligent IP cameras (such as those from Axis) and VMS platforms (like Milestone), MQTT allows for the following:
- Automated incident response: If a camera detects an anomaly—such as a machine operating outside its designated parameters—it can send an MQTT message to the machine to initiate an automated shutdown.
- Dynamic camera control: MQTT triggers can instruct cameras to pan, zoom, or focus on an area of interest based on sensor input or system rules.
- Real-time alerts: Events such as overheating, vibrations, or unauthorised access can instantly trigger system-wide alerts.
This connectivity turns surveillance from passive observation into proactive, autonomous control.
OPC UA: Industrial Interoperability and Standardised Communication
OPC UA (Open Platform Communications Unified Architecture) is a machine-to-machine communication protocol widely adopted in industrial automation.
Unlike MQTT, which is optimised for lightweight messaging, OPC UA focuses on standardised, secure, and structured data exchange between devices and systems across a manufacturing environment. OPC UA offers:
- Seamless interoperability: It enables different hardware and software systems from multiple vendors to share data efficiently.
- Context-rich communication: OPC UA transmits structured information including machine status, parameters, historical data, and alarms.
- Security by design: The protocol includes encryption, authentication, and auditing to protect industrial data.
In the context of smart video systems, OPC UA can be used to connect VMS platforms and cameras to SCADA systems, PLCs, and other operational technologies—enabling broader integration and system-wide visibility into production and safety workflows.
Audio-over-IP: Real-Time, Automated Safety Messaging
While visual surveillance is crucial, real-time audio communication can dramatically enhance health and safety outcomes. Audio-over-IP (AoIP) systems use the same IP infrastructure as your networked video to deliver pre-recorded or live messages over factory tannoy systems.
Here’s how AoIP, when integrated with VMS, helps:
- Automatic voice alerts: When a safety rule is breached (e.g., a worker enters a hazardous area without PPE), the system can trigger a voice message instantly, guiding the worker to take corrective action.
- Emergency response coordination: In case of fire, spill, or mechanical failure, voice announcements triggered by the VMS can provide clear evacuation instructions.
- Behavioural reinforcement: Routine messages can be scheduled or triggered to promote compliance without relying on human intervention.
This audio layer brings clarity and urgency to factory floor responses—ensuring safety policies are actioned instantly.
Video Management Systems (VMS) – Milestone XProtect: The Intelligence Engine
The Video Management System acts as the brain behind smart surveillance, orchestrating data from cameras, sensors, and shop floor machinery.
Milestone XProtect’s VMS rule engine for example, enables automated, event-driven actions across integrated devices, enhancing system responsiveness and operational efficiency. Capabilities include:
- Rule-based automation: The VMS can be programmed to perform actions—like, logging events, or sending alerts based on defined conditions.
- Analytics integration: AI-based object detection, line crossing, temperature monitoring, or license plate recognition can be layered onto video streams.
- Historical playback and reporting: Compliance reports and incident reviews become easier and faster, with metadata-enhanced footage.
Beyond visual management, AI-driven analytics within VMS platforms are now playing a pivotal role in optimising production and quality assurance. By analysing real-time video data, AI can:
- Detect early signs of mechanical issues: Such as overheating, abnormal vibrations, or pressure changes, before they escalate. This enables predictive maintenance, helping manufacturers avoid unplanned downtime and reduce costly equipment failures.
- Support greater uniformity and efficiency in quality control: By identifying product defects during production. These insights can be used to automatically adjust assembly line parameters like speed, rate, or acceleration, improving throughput and consistency without the need for capital-intensive upgrades.
- Generate detailed reports: That help teams identify root causes of recurring faults and operational inefficiencies, giving manufacturers the intelligence they need to prevent future issues and continuously improve performance
Real-World Impact: What This Means for Manufacturers
Together, MQTT, OPC UA, AoIP, and VMS deliver key benefits that address critical challenges faced by manufacturers:
Challenge |
Smart Factory Solution |
| Equipment damage from late detection | Real-time MQTT/OPC UA alerts trigger preventive shutdowns |
| Safety compliance issues | AoIP delivers immediate audio guidance on the floor |
| Manual monitoring costs | VMS automates detection, alerting, and response |
| Delayed incident response | Cameras and machines act instantly based on rule logic |
| Lack of audit trail | Metadata-rich video enables fast, detailed compliance reviews |
Conclusion
Manufacturers no longer have to choose between surveillance and automation, they can have both, tightly integrated into a single intelligent ecosystem.
With MQTT and OPC UA enabling machine-to-camera and system-to-system communication, Audio-over-IP ensuring real-time response, and VMS bringing the intelligence to tie it all together, the Smart Factory architecture offers a blueprint for proactive, efficient, and safe operations.
These technologies aren’t futuristic, they’re already available and being deployed by forward-thinking manufacturers using Axis Communications and Milestone Systems.
Ready to see how intelligent surveillance can transform your facility? Register for our upcoming Webinar: Beyond Surveillance: Unlocking Smart Automation with Axis & Milestone, taking place on Thursday 12th June at 10:00 AM. Click here for more information and to secure your place.
Advantex – A Manufacturers Partner of Choice
We’ve already helped manufacturers across the UK enhance security, safety, and operational insight with intelligent CCTV solutions. From delivering thermal surveillance at AMP Clean Energy’s low carbon centre, to protecting critical assets at NSK Bearings and supporting Plexus’ manufacturing facility—our work is shaping smarter, safer environments.
